Methods and Apparatus for Dispensing Solid Pharmaceutical Articles

ABSTRACT

A method is provided for dispensing solid pharmaceutical articles using an apparatus including a housing and a sensor system, the housing defining a dispensing passage having a dispensing inlet and a dispensing outlet downstream of the dispensing inlet, the sensor system including first and second sensors spaced apart along the dispensing channel such that the second sensor is located downstream of the first sensor. The method includes: forcing at least one article along a path through the dispensing passage; generating detection signals using the first and second sensors responsive to articles passing through the dispensing channel; and using the detection signals from the first and second sensors to monitor dispensing performance of the apparatus.

RELATED APPLICATION(S)

The present application is a continuation patent application of andclaims priority from U.S. patent application Ser. No. 11/834,936, filedAug. 7, 2007, which claims the benefit of U.S. Provisional PatentApplication No. 60/938,835, filed May 18, 2007, the disclosures of whichare hereby incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention is directed generally to the dispensing of solidpharmaceutical articles and, more specifically, is directed to theautomated dispensing of solid pharmaceutical articles.

BACKGROUND OF THE INVENTION

Pharmacy generally began with the compounding of medicines whichentailed the actual mixing and preparing of medications. Heretofore,pharmacy has been, to a great extent, a profession of dispensing, thatis, the pouring, counting, and labeling of a prescription, andsubsequently transferring the dispensed medication to the patient.Because of the repetitiveness of many of the pharmacist's tasks,automation of these tasks has been desirable.

Some attempts have been made to automate the pharmacy environment. Forexample, U.S. Pat. No. 6,971,541 to Williams et al. describes anautomated system for dispensing pharmaceuticals using dispensing bins.Each dispensing bin includes a hopper in which tablets are stored and adispensing channel fluidly connecting the hopper to a dispensing outlet.Forward and reverse air flows are used to selectively convey the tabletsthrough the dispensing channel in each of a dispensing direction (towardthe outlet) and a reverse direction (toward the hopper). A countingsensor is positioned proximate the outlet of the dispensing channel andused to detect tablets passing the sensor in order to maintain a countof the tablets dispensed.

SUMMARY OF THE INVENTION

According to some embodiments of the present invention, a method isprovided for dispensing solid pharmaceutical articles using an apparatusincluding a housing and a sensor system, the housing defining adispensing passage having a dispensing inlet and a dispensing outletdownstream of the dispensing inlet, the sensor system including firstand second sensors spaced apart along the dispensing channel such thatthe second sensor is located downstream of the first sensor. The methodincludes: forcing at least one article along a path through thedispensing passage; generating detection signals using the first andsecond sensors responsive to articles passing through the dispensingchannel; and using the detection signals from the first and secondsensors to monitor dispensing performance of the apparatus.

According to some embodiments of the present invention, an apparatus fordispensing solid pharmaceutical articles includes a housing, a drivemechanism and a sensor system. The housing defines a dispensing passagehaving a dispensing inlet and a dispensing outlet downstream of thedispensing inlet. The drive mechanism serves to force the articles alonga path through the dispensing passage between the dispensing inlet andthe dispensing outlet. The sensor system includes first and secondsensors operative to detect articles passing through the dispensingpassage and a controller to receive and use detection signals from thefirst and second sensors to monitor dispensing performance of theapparatus. The first and second sensors are spaced apart along thedispensing channel such that the second sensor is located downstream ofthe first sensor.

According to some embodiments of the present invention, a method isprovided for dispensing solid pharmaceutical articles using an apparatusincluding a housing and a sensor system, the housing defining adispensing channel having a dispensing inlet and a dispensing outletdownstream of the dispensing inlet, the sensor system including firstand second sensors positioned along the dispensing channel. The methodincludes: forcing at least one article along a path through thedispensing channel; generating detection signals using the first andsecond sensors responsive to articles passing through the dispensingchannel; and comparing the detection signals from the first and secondsensors to determine whether a dispensing fault condition has occurred.

According to some embodiments of the present invention, a method isprovided for dispensing solid pharmaceutical articles using an apparatusincluding a housing and a sensor system, the housing defining adispensing channel having a dispensing inlet and a dispensing outletdownstream of the dispensing inlet, the sensor system including at leastone sensor positioned along the dispensing channel. The method includes:forcing at least one article along a path through the dispensingchannel; generating detection signals using the at least one sensorresponsive to articles passing through the dispensing channel; and usinga duration of at least one of the detection signals from the at leastone sensor to determine whether a dispensing fault condition hasoccurred.

Further features, advantages and details of the present invention willbe appreciated by those of ordinary skill in the art from a reading ofthe figures and the detailed description of the preferred embodimentsthat follow, such description being merely illustrative of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart illustrating methods according to embodiments ofthe present invention.

FIG. 2 is a perspective view of a pharmaceutical tablet dispensingsystem including a sensor system according to embodiments of the presentinvention.

FIG. 3 is a cutaway view of the tablet dispensing system of FIG. 2illustrating a container dispensing station, a labeling carrier, adispensing carrier, and a closure dispensing station thereof.

FIG. 4 is a front perspective view of a dispensing bin according toembodiments of the present invention.

FIG. 5 is a cross-sectional view of the bin of FIG. 4 filled withtablets at rest.

FIG. 6 is a cross-sectional view of the bin of FIG. 4 wherein tabletscontained therein are being agitated and dispensed in a forward ordispensing direction.

FIG. 7 is a cross-sectional view of the bin of FIG. 4 wherein a tabletis being returned to a hopper of the bin in a reverse direction.

FIG. 8 is a block diagram representing a sensor system and controlvalves of the pharmaceutical dispensing system of FIG. 1.

FIGS. 9-13 are schematic diagrams representing detection pulse signalsof an entrance sensor and an exit sensor of the sensor system of FIG. 8over time.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which illustrativeembodiments of the invention are shown. In the drawings, the relativesizes of regions or features may be exaggerated for clarity. Thisinvention may, however, be embodied in many different forms and shouldnot be construed as limited to the embodiments set forth herein; rather,these embodiments are provided so that this disclosure will be thoroughand complete, and will fully convey the scope of the invention to thoseskilled in the art.

It will be understood that when an element is referred to as being“coupled” or “connected” to another element, it can be directly coupledor connected to the other element or intervening elements may also bepresent. In contrast, when an element is referred to as being “directlycoupled” or “directly connected” to another element, there are nointervening elements present. Like numbers refer to like elementsthroughout.

In addition, spatially relative terms, such as “under”, “below”,“lower”, “over”, “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. It will beunderstood that the spatially relative terms are intended to encompassdifferent orientations of the device in use or operation in addition tothe orientation depicted in the figures. For example, if the device inthe figures is turned over, elements described as “under” or “beneath”other elements or features would then be oriented “over” the otherelements or features. Thus, the exemplary term “under” can encompassboth an orientation of over and under. The device maybe otherwiseoriented (rotated 90 degrees or at other orientations) and the spatiallyrelative descriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof. As used herein the expression“and/or” includes any and all combinations of one or more of theassociated listed items.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art andwill not be interpreted in an idealized or overly formal sense unlessexpressly so defined herein.

In accordance with embodiments of the present invention apparatus andmethods are provided for dispensing solid pharmaceutical articles. Inparticular, such methods and apparatus may be used to dispensepharmaceuticals. With reference to FIG. 1, methods according toembodiments of the present invention may be executed using an apparatusincluding a housing, a flow generator, and a sensor system, the housingdefining a dispensing channel having a dispensing inlet and a dispensingoutlet downstream of the dispensing inlet, the sensor system includingfirst and second sensors spaced apart along the dispensing channel suchthat the second sensor is located downstream of the first sensor. Atleast one drive gas flow is generated using the flow generator to forceat least one article along a path through the dispensing channel (Block20). The dispensing channel may or may not be fully enclosed. Responsiveto articles passing through the dispensing channel, detection signalsare generated using the first and second sensors (Block 22). Thedetection signals from the first and second sensors are used to monitordispensing performance of the apparatus (Block 24). According to someembodiments, the articles are pharmaceutical tablets.

A dispensing system according to embodiments of the present inventionand that can carry out the foregoing methods is illustrated in FIGS. 2-8and designated broadly therein at 40 (FIGS. 2 and 3). The dispensingsystem 40 includes a sensor system 102 (FIG. 8) according to embodimentsof the present invention. The system 40 includes a support frame 44 forthe mounting of its various components. Those skilled in this art willrecognize that the frame 44 illustrated herein is exemplary and can takemany configurations that would be suitable for use with the presentinvention. The frame 44 provides a strong, rigid foundation to whichother components can be attached at desired locations, and other frameforms able to serve this purpose may also be acceptable for use withthis invention.

The system 40 generally includes as operative stations a controller(represented herein by a graphical user interface 42), a containerdispensing station 58, a labeling station 60, a tablet dispensingstation 62, a closure dispensing station 64, and an offloading station66. In the illustrated embodiment, containers, tablets and closures aremoved between these stations with a dispensing carrier 70; however, insome embodiments, multiple carriers are employed. The dispensing carrier70 has the capability of moving the container to designated locationswithin the cavity 45 of the frame 44. Except as discussed herein withregard to the dispensing station 62, each of the operative stations andthe conveying devices may be of any suitable construction such as thosedescribed in detail in U.S. Pat. No. 6,971,541 to Williams et al. and/orU.S. Patent Publication No. US-2006-0241807-A1, the disclosures of whichare hereby incorporated herein in their entireties.

The controller 42 controls the operation of the remainder of the system40. In some embodiments, the controller 42 will be operatively connectedwith an external device, such as a personal or mainframe computer, thatprovides input information regarding prescriptions. In otherembodiments, the controller 42 may be a stand-alone computer thatdirectly receives manual input from a pharmacist or other operator. Anexemplary controller is a conventional microprocessor-based personalcomputer.

In operation, the controller 42 signals the container dispensing station58 that a container of a specified size is desired. In response, thecontainer dispensing station 58 delivers a container for retrieval bythe carrier 70. From the container dispensing station 58, the containeris moved to the labeling station 60 by the carrier 70. The labelingstation 60 includes a printer that is controlled by the controller 42.The printer prints and presents an adhesive label that is affixed to thecontainer.

Filling of labeled containers with tablets is carried out by the tabletdispensing station 62. The tablet dispensing station 62 comprises aplurality of tablet dispensing bin assemblies or bins 100 (described inmore detail below), each of which holds a bulk supply of individualtablets (typically the bins 100 will hold different tablets). Referringto FIGS. 4 and 5, the dispensing bins 100, which may be substantiallyidentical in size and configuration, are organized in an array mountedon the rails of the frame 44. Each dispensing bin 100 has a dispensingpassage or channel 120 with an outlet 124 that faces generally in thesame direction, to create an access region for the dispensing carrier70. The identity of the tablets in each bin is known by the controller42, which can direct the dispensing carrier 70 to transport thecontainer to the proper bin 100 to fill the particular prescription. Insome embodiments, the bins 100 may be labeled with a bar code or otherindicia to allow the dispensing carrier 70 to confirm that it hasarrived at the proper bin 100.

The dispensing bins 100 are configured to singulate, count, and dispensethe tablets contained therein, with the operation of the bins 100 andthe counting of the tablets being controlled by the controller 42. Someembodiments may employ the controller 42 as the device which monitorsthe locations and contents of the bins 100; others may employ thecontroller 42 to monitor the locations of the bins, with the bins 100including indicia (such as a bar code or electronic transmitter) toidentify the contents to the controller 42. In still other embodiments,the bins 100 may generate and provide location and content informationto the controller 42, with the result that the bins 100 may be moved todifferent positions on the frame 42 without the need for manualmodification of the controller 42 (i.e., the bins 100 will update thecontroller 42 automatically).

Any of a number of dispensing units that singulate and count discreteobjects may be employed if suitably modified to include the inventiveaspects disclosed herein. In particular, dispensing units that rely upontargeted air flow and a singulating nozzle assembly may be used, such asthe devices described in U.S. Pat. No. 6,631,826 to Pollard et al.and/or U.S. Patent Publication No. US-2006-0241807-A1, each of which ishereby incorporated herein by reference in its entirety. Bins of thisvariety may also include additional features, such as those describedbelow.

After the container is desirably filled by the tablet dispensing station62, the dispensing carrier 70 moves the filled container to the closuredispensing station 64.

The closure dispensing station 64 may house a bulk supply of closuresand dispense and secure them onto a filled container. The dispensingcarrier 70 then moves to the closed container, grasps it, and moves itto the offloading station 66.

Turning to the bins 100 in more detail, an exemplary bin 100 is shown inmore detail in FIGS. 4-8. The bin 100 includes a housing 110 having ahopper portion 112 and a nozzle 114.

Referring to FIG. 6, the hopper portion 112 defines a hopper chamber112A that can be filled with tablets T. A lower screen 130A is providedin the floor of the hopper portion 112 and an upper screen 130B isprovided in the ceiling of the hopper portion 112. As discussed below,air or other suitable gas can be flowed through the screens 130A, 130Band the chamber 112A to agitate the tablets T contained therein.

With reference to FIG. 5, the nozzle 114 defines a dispensing channel120 through which the tablets T can be dispensed one at a time. Thedispensing channel 120 has an inlet 122 adjacent and fluidly connectingthe channel 120 to the chamber 112A. The dispensing channel 120 has anoutlet 124 downstream from and opposite the inlet 122 and through whichtablets may exit the nozzle 114 to be dispensed into the container C(FIG. 7).

The housing 110 further includes a low pressure port 132 and a highpressure nozzle 134 (FIGS. 4 and 6). A door 132A is provided toselectively open and close the port 132 by operation of an associatedsolenoid 132B.

With continued reference to FIG. 5, a forward jet passage 140 is fluidlyconnected to the high pressure nozzle 134 and terminates in a forwardjet aperture 140A at the dispensing channel 120. A forward control valve142 is operable to control airflow to the jet aperture 140A. A rearwardor reverse jet passage 144 is also fluidly connected to the highpressure nozzle 134 and terminates in a rearward or reverse jet aperture144A at the dispensing channel 120. A reverse control valve 146 isoperable to control airflow to the jet aperture 144A.

According to some embodiments and as described in U.S. PatentPublication No. US-2006-0241807-A1, the tablet dispensing station 62includes a low pressure manifold 74 fluidly connected to a low pressuresource such as a vacuum motor (not shown), which provides low level(i.e., about 2 psi) suction to draw air FA through (in succession) thescreen 130A, the chamber 112A, the screen 130B and the port 132 toagitate tablets within the hopper chamber 112A (FIG. 6). Also, a highpressure (i.e., about 30 psi) conduit 72 fluidly connected to a highpressure source (not shown) is fluidly connected to the high pressurenozzle 134 to supply high pressure air to the jet apertures 140A, 144A.Further, a connector circuit board 77 is mounted horizontally below themanifold 74. The circuit board 77 or other electrical connector providesan electrical connection between the controller 42 and a bin-controllingcircuit board 78 (or other electronic component) of the bin 100 forpower and data signals to/from the controller 42.

The sensor system 102 includes a front or exit sensor 80 and a rear orentrance sensor 84 positioned along the channel 120. The exit sensor 80is located downstream (i.e., in the forward or dispensing direction ofthe tablet flow path through the dispensing channel 120) from theentrance sensor 84 along the dispensing channel 120. The exit sensor 80is mounted in the nozzle 114 proximate the outlet 124 and distal fromthe inlet 122 and faces the channel 120. The entrance sensor 84 ismounted in the nozzle 114 proximate the inlet 122 and distal from theoutlet 124 and also faces the channel 120. The sensors 80, 84 are tabletdetecting sensors and are operably connected to associated sensorreceiver/processor electronics. The sensors 80, 84 may be electricallyconnected to an associated controller by lead wires 80A, 84A. Accordingto some embodiments, the associated controller is or includes thecontroller 42 and/or the circuit board 78. As further discussed below,the sensors 80, 84 are configured and positioned to detect the tablets Tas they pass through the dispensing channel 120. The sensors 80, 84 andthe associated controller 42 together comprise a sensor system 102operative to monitor flow of tablets T through the channel 120 and,thereby, dispensing performance of the bin 100. According to someembodiments, the controller 42 uses detection signals from at least oneof the sensors 80, 84 to count the dispensed tablets. According to someembodiments, at least the exit sensor 80 is used for this purpose. Insome cases, the sensor system operates the valves 142, 146 or otherdevices in response to identified or determined conditions orperformance in dispensing. While two sensors 80, 84 are describedherein, apparatus and methods according to embodiments of the presentinvention may use sensor systems that use more than two tablet detectionsensors along the flow path.

According to some embodiments, the sensors 80, 84 are photoelectricsensors. According to some embodiments, the sensors 80, 84 are infrared(IR) sensors. According to some embodiments, photoemitters 82 and 86(e.g., IR emitters) are mounted in the nozzle opposite the sensors 80and 84, respectively, to emit photoemissions toward the respectivesensors 80, 84 across the channel 120. The photoemitters 82, 86 may beoperatively connected to the controller 42 or circuit board 78 by wires82A, 86A. According to some embodiments, all or some of the components80, 84 and 82, 86 may include both a photoemitter and a photodetector,whereby the components 82, 86 may also serve as sensors. For the purposeof explanation, the illustrated embodiment will be described with onlythe components 80, 84 being sensors (i.e., the sensors 80, 84 receivephotoemissions from the photoemitters 82, 86). Other types of sensorsmay be employed as well. Other suitable types of sensors may include,for example, UV, RF, capacitive and EMF sensors.

The exit sensor 80 and the entrance sensor 84 are spaced apart along thechannel 120 a distance D (FIG. 5). The preferred or minimum distance Dmay be determined by the type of sensor and/or other parameters orarrangements or physical limitations of the components. According tosome embodiments, the distance D should be large enough to preventcross-talk between the components and to provide two distinct signalsfrom the respective sensors 80, 84. The minimum distance D may also belimited or determined by the time needed to prevent an extra pill fromexiting the channel 120 (i.e., once the requested count is reached, thedistance D should allow enough time to stop an extra pill from exiting).

According to some embodiments, the entrance sensor 84 is positionedalong the channel 120 at, in or immediately adjacent the inlet 122.According to some embodiments, the exit sensor 80 is positioned alongthe channel 120 at, in or immediately adjacent the outlet 124.

Exemplary operation of the dispensing system 40 will now be described.The bin 100 is filled with tablets T to be dispensed. The tablets T mayinitially be at rest as shown in FIG. 5. At this time, the valves 142,146 are closed so that no gas flow is provided through the jet outlets140A, 144A.

To fill the container C, the dispensing carrier 70, directed by thecontroller 42, moves the container C to the exit port of the selecteddispensing bin 100. The controller 42 signals the solenoid 132B to openthe door 132A. This opening of the door 132A draws low pressure air upthrough the hopper chamber 112A to the manifold 74, thereby agitatingthe tablets T contained in the hopper chamber 112B.

Once agitation has commenced, the controller 42 signals the forwardvalve 142 to open (while the reverse valve 146 remains closed). Theopened valve 142 permits the pressurized gas from the gas source 72 toflow through the passage 140 and out through the forward drive jetoutlet 140A. The pressurized flow from the jet outlet 140A creates ahigh velocity gas jet that generates suction that causes a forward flowFF of high pressure, high velocity air to be drawn outwardly through thedispensing channel 120 in a dispensing direction (FIG. 6). Tablets T areoriented into a preferred orientation by the shape of the inlet 122 tothe dispensing channel 120 and dispensed into the container C throughthe dispensing channel 120 and the outlet 124 under the force of theforward flow FF.

Once dispensing is complete (i.e., a predetermined number of tabletshave been counted by the controller 42 as dispensed), the controller 42activates the forward valve 142 to close and the reverse valve 146 toopen. The opened valve 146 permits the pressurized gas from the gassource 72 to flow through the passage 144 and out through the reversedrive jet outlet 144A. The pressurized flow from the jet outlet 144Acreates a high velocity gas jet that generates suction that causes areverse (i.e., rearward) flow FR of high pressure air to be drawninwardly through the dispensing channel 120 toward the chamber 112A in areverse or return direction. In this manner, the airflow is reversed andany tablets T remaining in the channel 120 are returned to the chamber112A under the force of the reverse flow (FIG. 7).

While, in the foregoing description, the controller 42 controls thevalves 142, 146, the valves 142, 146 may alternatively be controlled bya local controller unique to each bin 100. The bin 100 can be filled orreplenished with tablets via access from a pivoting door 127 (FIG. 5)located at the upper rear portion of the bin 100, for example. Asdisclosed in U.S. Patent Publication No. US-2006-0241807-A1, the bin 100may include components that permit the entry to the dispensing channel120 to be adjusted in size to complement the size and configuration ofthe tablet to be dispensed.

During the dispensing phase (i.e., when the forward flow FF is beinggenerated), a tablet jam may occur. A tablet jam is a condition whereinone or more tablets are caught up in the bin 100 such that tablets Twill not feed into or through the dispensing channel 120 under the forceof the forward flow FF. A jam is indicated if the entrance sensor 84 hasnot detected a pill within a specified time period (e.g., one second).When a tablet jam is identified by the controller 42, the controller 42will close the forward valve 142 and open the reverse valve 146 togenerate the reverse flow FR to clear a perceived tablet jam. Thisaction of the controller 42 may be referred to as issuing a “jam clear”.

According to some embodiments, the controller 42 will execute acalibration procedure between dispensing sessions (i.e., between the endof a forward flow FF and the initiation of the next forward flow FF) inorder to calibrate the sensors 80, 84. According to some embodiments,the calibration procedure includes opening the reverse valve 146 togenerate the reverse flow FR while calibrating the sensors 80, 84. Thismay ensure that no tablets or tablet fragments occlude the sensors 80,84 and thereby corrupt the calibration. The controller 42 may conductthe calibration procedure automatically and/or shortly or immediatelyafter a dispensing session and the bin 100 may remain idle (i.e., withneither a forward flow FF nor a reverse flow FR being generated) duringan idle period between the end of the calibration reverse flow FR andthe initiation of the next dispensing session.

Typically, an operator will request that a desired number of tablets bedispensed (“the requested count”). The sensors 80, 84 detect the tabletsT as they pass through predetermined points in the dispensing channel120, as discussed in more detail below. The controller 42 uses thedetection signals from the sensors 80, 84 to monitor and maintain aregistered count of the tablets T dispensed (“the system count”). Whenthe system count matches the requested count, the controller 42 willdeem the dispensing complete and cease dispensing of the tablets T. Ifthe controller miscounts the tablets actually dispensed, there may be amismatch between the requested count and the final actual count.

In practice and in the absence of the apparatus and methods of thepresent invention, the foregoing processes may suffer from various faultconditions or other dispensing concerns. In prior art systems of thetype employing only a single counting sensor or set of counting sensorsat one location along the dispensing channel (e.g., at the exit end) todetect tablets in the dispensing channel (hereinafter referred to as“prior art single sensor systems”), these fault conditions may result ininaccurate counts such as counting a tablet that is not dispensed,failing to count a tablet that is dispensed, or failing to recognize apartial tablet.

The foregoing concerns may be addressed by the sensor system 102 of thebin 100 and methods in accordance with embodiments of the presentinvention. According to some embodiments, the entrance sensor 84proximate the inlet 122 of the channel 120 performs the duty ofdetecting tablet jams and the exit sensor 80 proximate the exit oroutlet 124 performs the duty of counting the dispensed tablets. Byseparating these two functions, the exit sensor 80 (i.e., the countsensor) can be guarded by the entrance sensor 84 (i.e., the jam sensor)to ensure that no tablets are in the dispensing channel 120 during a jamclear. The two sensors 80, 84 can also be cooperatively employed todetect and identify other modes of failure.

Such failure modes are called “exception events” and arise when thesensor output does not follow the expected pulse width and travel timesfor a singulated pill in standard operation of the bin 100. Someexception events and corresponding operations of the bin 100 that may beencountered will be described hereinbelow. However, it will beappreciated that this description is not exhaustive of the advantageoususes of the apparatus in accordance with embodiments of the presentinvention.

In some cases, two or more tablets T may be disposed or “preloaded” inthe channel 120 in or closely adjacent the inlet 122 prior to actuationof the forward valve 142 to generate the forward flow FF. This conditionmay be referred to as a “preload dispensing fault condition”. A preloaddispensing fault condition may occur when tablets in the dispensingchannel 120 are not fully returned to the hopper chamber 112A by areverse flow or “jam clear” intended to clear the dispensing channel120, for example. A preload dispensing fault condition may also occurwhen tablets unintentionally migrate into the dispensing channel 120from the hopper. For example, during the idle period between a jam clearor other reverse flow FR and the initiation of the next forward flow FF,tablets may slide or vibrate out of the hopper chamber 112A and into theinlet 122 or the dispensing channel 120. In prior art single sensorsystems, upon initiation of the forward flow FF, the two or morepreloaded tablets may travel down the channel 120 in contact with orvery closely adjacent one another so that the two or more tablets passthe counting sensor (which is typically located proximate the dispensingoutlet) together. The counting sensor may generate only a single, extralong detection pulse for the two or more tablets rather than two or morediscrete pulses that are required to register a count of two or moretablets. As a result, two or more tablets are dispensed through thedispensing outlet but the system count of dispensed tablets is onlyincremented by one tablet.

In accordance with embodiments of the present invention, a preloaddispensing fault condition can be identified and corrected by monitoringthe entrance sensor 84. More particularly, the entrance sensor 84 isconfigured and located with respect to the dispensing channel 120 andthe inlet 122 such that, in the case of a preload dispensing faultcondition, one or more of the tablets will occlude the entrance sensor84. When this condition occurs prior to initiation of the forward flowFE, the entrance sensor 84 will provide a detection signal to thecontroller 42 indicating that the one or more tablets is/are at theentrance sensor 84. In response to the detection signal from theentrance sensor 84 prior to initiating the forward flow FF, thecontroller 42 identifies the existence of the preload dispensing faultcondition. Further in response, the controller 42 will thereafter openthe reverse valve 146 to generate the reverse flow FR to force anytablets T lingering in the channel 120 back into the hopper chamber112A. In this manner, the channel 120 is cleared and the preloaddispensing fault condition is removed prior to the onset of tabletdispensing.

A preload dispensing fault may also occur wherein the preloaded tabletor tablets are disposed in the dispensing channel 120 between theentrance sensor 84 and the exit sensor 80 prior to actuation of theforward valve 142 to generate the forward flow FF. The preloaded tabletsmay not occlude the entrance sensor 84. According to some embodiments ofthe present invention, preload dispensing fault conditions of this typeare identified and corrected by continuously monitoring the entrancesensor 84 even when the bin 100 is idle. According to some embodiments,the entrance sensor 84 is continuously monitored at least from the endof the actuation of the reverse flow FR during calibration as discussedabove to the start of the forward flow FF to begin a dispensing session(i.e., the idle period). According to some embodiments, the entrancesensor 84 is also continuously monitored throughout the calibrationperiod. According to some embodiments, the entrance sensor 84 iscontinuously monitored at all times. If a tablet is detected by theentrance sensor 84 during the idle period, the controller 42 identifiesthe existence of a preload dispensing fault condition. The controller 42may respond to the identified fault condition by generating the reverseflow FR to force any tablets lingering in the channel 120 back into thehopper chamber 112A. In this manner, the channel 120 is cleared and thepreload dispensing fault condition is removed prior to the onset oftablet dispensing.

The sensor system 102 may employ the following method to address a“tandem dispensing fault condition.” With reference to FIG. 9, when atandem dispensing fault condition is present, the controller 42 maygenerate the forward flow FF to dispense the tablets as discussed abovewith regard to the prior art single sensor systems. This may occur ifthe entrance sensor 84 is not relied upon to sense preloaded tablets orthe tandem condition is not detectable because theconfiguration/locations of the tablets do not cause the sensor 84 toimmediately start with a tablet detection. The outputs of the sensors80, 84 are monitored by the controller 42 and compared. Each of the twotablets passes the entrance sensor 84 in immediate succession, whichcauses the entrance sensor to generate a single pulse P2 as representedby the signal pulse graph A) of FIG. 9. The signal pulse P2 has aduration that is larger than that of a prescribed or average referenceduration for a single tablet passing the sensor 84 during dispensing.Thereafter, the two tablets pass the exit sensor 80 in immediatesuccession, which causes the exit sensor 80 to generate one continuous,long duration signal pulse P4 as represented by the detector pulse graphB) of FIG. 9. The signal pulse P4 has a duration that is larger thanthat of a prescribed or average reference duration for a single tabletpassing the sensor 80 during dispensing. The controller 42 compares thedurations of the signals P2, P4 with the corresponding expected oraverage signal pulse durations and also compares the time TBP betweenthe pulses P2, P4 with the expected or average time between pulses forstandard operation, and determines that a tandem dispensing faultcondition has occurred. In response, the controller 42 may increment thesystem dispensed count by an appropriate amount and/or alert anoperator. The expected or average signal pulse durations for the sensors80, 84 and the expected or average time between the pulses of thesensors 80, 84 may be determined using average entrance, exit and nozzlevelocities determined as described below.

In some cases, a first tablet T lingers in the dispensing channel 120during dispensing so that a second tablet T catches up to and collideswith the first tablet before the first tablet is detected or completelydetected by a counting sensor. The second tablet travels down thechannel 120 in contact with the first tablet so that the first andsecond tablets pass the counting sensor together, responsive to whichthe counting sensor generates a single, extended duration signal pulse.This condition may be referred to as a “collision dispensing faultcondition”. In prior art single sensor systems, the single, extendedduration signal pulse may simply be counted as a single tablet. As aresult, two tablets are actually dispensed from the outlet but thesystem tablet dispense count is only incremented by one tablet.

In accordance with embodiments of the present invention, a collisiondispensing fault condition can be identified and corrected by monitoringthe exit sensor 80 and the entrance sensor 84. More particularly, theoutputs of the exit sensor 80 and the entrance sensor 84 are monitoredby the controller 42 and compared. In the case of a collision dispensingfault condition, each of the two tablets passes the entrance sensor 84in turn and with spacing between the tablets, which causes the entrancesensor 84 to generate two discrete signal pulses P10, P12 in sequenceover time, as represented by the signal pulse graph A) of FIG. 10. Thesetwo pulses P10, P12 have a duration corresponding to a typical singletablet. Thereafter, the two tablets pass the exit sensor 80 in immediatesuccession, which causes the exit sensor 80 to generate one longduration signal pulse P14 as represented by the detector pulse graph B)of FIG. 10. The controller 42 compares the signals P10, P12, P14 fromthe sensors 80, 84 and determines that a collision dispensing faultcondition has occurred. In response, the controller 42 may increment thesystem dispensed count total by the appropriate amount (in this example,two). Alternatively, in response, the controller 42 may issue an alertto an operator or the like indicating that a tablet may have beendispensed but not counted.

In some cases in prior art single sensor systems, a tablet that has beenpreviously detected by a count sensor and counted by the sensor asdispensed is drawn back into or through the dispensing channel by areverse drive gas flow FR (i.e., the tablet is aspirated back into thedispensing channel or hopper chamber). This occurrence may be referredto as an “aspiration dispensing fault condition”. In prior art singlesensor systems, the system count will exceed the actual number ofdispensed tablets.

In accordance with embodiments of the present invention, an aspirationdispensing fault condition can be identified and corrected by monitoringthe exit sensor 80 and the entrance sensor 84, and the direction ofdrive gas flow. More particularly, the outputs of the exit sensor 80 andthe entrance sensor 84 are monitored by the controller 42 and compared.Each signal pulse from the exit sensor 80 will be accounted for ifpreceded by a corresponding signal pulse from the entrance sensor 84.Under normal (nonfault) conditions, each tablet drawn from the hopper112A passes the entrance sensor 84 and then the exit sensor 80 andgenerates corresponding signal pulses in sequence. In the case of anaspiration dispensing fault condition, a tablet previously counted asdispensed passes the exit sensor 80, which causes the exit sensor 80 togenerate a signal pulse P20 as represented by the detector pulse graphB) of FIG. 11. Thereafter, the tablet passes the entrance sensor 84,which causes the entrance sensor 84 to generate a signal pulse P22 asrepresented by the detector pulse graph A) of FIG. 11. The controller 42determines that the drive gas flow was in the reverse direction when thepulses P20, P22 were generated and compares the signals P20, P22 fromthe sensors 80, 84. The controller determines that the exit signal pulseP20 did not have a corresponding preceding entrance sensor pulse and theexit sensor detection pulse P20 was triggered or generated prior to theentrance sensor detection pulse P22. From this, the controller 42determines that an aspiration dispensing fault condition has occurred.In response, the controller 42 may decrement the system dispensing counttotal by one. Alternatively, in response, the controller 42 may issue analert to an operator indicating that a tablet may have been counted andthereafter aspirated.

In some cases in prior art single sensor systems, jams are detectedusing the single sensor, which is typically positioned proximate theoutlet of the dispensing channel. If, when the forward drive gas flow isbeing generated, some prescribed length of time (e.g., 1.0 second)passes without a tablet being detected by the single sensor, the systemwill issue a reverse drive gas flow in order to clear an upstream jam inthe dispensing channel (i.e., the presumed cause of the failure todetect a tablet at the sensor). However, because of the length of timerequired for a tablet to travel from the entrance, the reverse drive gasjet flow may be initiated while a tablet is in fact en route to the exitcount sensor such that the tablet occludes the count sensor, reversesdirection in the dispensing channel, and returns back to the hopperchamber. This occurrence may be referred to as a “tablet reversaldispensing fault condition”. In prior art single sensor systems, thetablet may be counted as dispensed and the reversal may not beregistered so that the system count is increased over the actual numberof tablets dispensed by one. Moreover, in some cases, the reversedtablet may be counted twice (once when passing the count sensor in thedispensing direction and once when passing the count sensor in thereverse direction).

In accordance with embodiments of the present invention, a tabletreversal dispensing fault condition is prevented by triggering thereverse drive gas flow (jam clear) off of the entrance sensor 84 insteadof the counting sensor 80. More particularly, the controller 42 monitorsthe entrance sensor 84. If a tablet is not detected by the entrancesensor 84 within a prescribed length of time (wait time) while theforward drive gas flow (i.e., the dispensing flow) is being generated,the controller 42 will identify a tablet jam condition. Responsive tothe tablet jam condition, the controller 42 will issue a jam clear(i.e., open the reverse valve 146 to generate a burst or sustainedreverse flow FR). In this manner, the entrance sensor 84 “guards” theexit sensor 80.

The sensor system 102 may additionally or alternatively employ thefollowing method to identify and correct a tablet reversal dispensingfault condition by monitoring the exit sensor 80, the entrance sensor84, and the direction of drive gas flow. The outputs of the exit sensor80 and the entrance sensor 84 are monitored by the controller 42 andcompared. In the case of a tablet reversal dispensing fault condition, atablet passes the entrance sensor 84 (which causes the entrance sensor84 to generate a typical duration signal pulse P30 as represented by thedetector pulse graph A) of FIG. 12), thereafter passes the exit sensor80 (which causes the exit sensor 80 to generate an extra long durationsignal pulse (or two signal pulses as shown by the dotted line) P32 asrepresented by the detector pulse graph B) of FIG. 12), and thereafteragain passes the entrance sensor 84 (which causes the entrance sensor 84to generate a typical duration signal pulse P34). The controller 42determines that the drive gas flow was in the forward direction duringthe pulse P30 and in the reverse direction during the pulse P34,compares the signals P30, P32, P34 from the sensors 80, 84, anddetermines that a tablet reversal dispensing fault condition hasoccurred. In response, the controller 42 may decrement the dispensingcount total by one. Alternatively, in response, the controller 42 mayissue an alert to an operator indicating that a tablet may have beencounted and thereafter reversed.

While events such as those described above may be characterized byspecific sequences of events, the sensor system 102 may also deriveinformation about the events themselves or the dispensing systemoperation from the information embodied in the sensor signals (e.g., inthe sensor signal pulse trains), comparison between the outputs of thesensors 80, 84, and externally determined or known information about thetablets and tablet flow direction.

The sensor system 102 may allow for measurement of speed and timerelated to tablet dispensing. According to some embodiments, the lengthof a complete prescribed tablet (hereinafter, “Tablet Length”) is known.With reference to FIG. 13, for each tablet dispensed through the channel120, the controller 42 will receive a detection signal pulse JP from theentrance sensor 84 and a detection signal pulse CP from the exit sensor80. The pulse JP has a duration or width JPW corresponding to theduration of occlusion of the sensor 84 by the tablet. Likewise, thepulse CP has a duration or width CPW corresponding to the duration ofocclusion of the sensor 80 by the tablet. The controller 42 determinesthe velocity of each tablet through the outlet 124 (its “exit velocity”)and the velocity of the tablet through the inlet 122 (its “entrancevelocity”) using the pulse widths JPW, CPW and the known Tablet Length.More particularly, the exit velocity can be calculated as:

Tablet Length/Pulse width CPW=exit velocity

The entrance velocity can be calculated as:

Tablet Length/Pulse width JPW=entrance velocity

Additionally, the controller can determine the velocity at which thetablet travels through the channel 120 (nozzle velocity) using the knowndistance (“sensor distance”; e.g., the distance D (FIG. 5)) between theoperative trailing edge of the signal from the sensor 84 and theoperative trailing edge of the signal from the sensor 80, and themeasured time between pulses (TBP) (i.e., the duration between the endtimes CP End and JP End of the pulses CP and JP (i.e., the trailingedges of the pulses CP and JP), respectively). Using the trailing edges(CP End and JP End) may assist in determining when an event is over;however, the start times of the pulses CP, JP can be used instead. Moreparticularly, the nozzle velocity can be calculated as:

sensor distance/(CP End−JP End)=nozzle velocity

From these measurements and prescribed values, the controller 42 can“learn” or determine the average exit velocity, the average entrancevelocity, and the average nozzle velocity for tablets dispensed throughthe channel 120. These average values can be applied to specific events(i.e., dispensed tablets) to identify or evaluate additionalcharacteristics of the events.

According to some embodiments, when the pulses CP, JP for a given tabletindicate that the tablet has passed through the channel 120 at theaverage nozzle velocity but one or both of the pulses CP, JP has aduration that is less than the average by more than a prescribed amount(e.g., one or two standard deviations), the controller 42 will identifythe tablet as a partial tablet (i.e., a tablet having a length less thanthe prescribed or standard length for the tablets). Using the pulseduration or width measurements, the known tablet length, and the typicaltime between signal pulses, the sensor system 102 can determine thenumber of whole tablets and partial tablets that are dispensed, and eventhe sizes of the partial tablet fragments.

According to some embodiments, when a detection signal pulse CP, JP froma sensor 80, 84 has a duration that exceeds the average pulse for thatsensor by more than a prescribed amount (e.g., one or two standarddeviations), the controller 42 will identify an exception event. Thecontroller 42 may further evaluate and catalog the exception event usingthis and additional available performance information. The controller 42may assess the measured data and compare the measured data to theexpected data for known specific events to identify a specific eventcorresponding to the measured data. Once the event or event type isidentified, the controller may perform appropriate corrective action tothe count, if any exists. The controller 42 may incorporate the statesof the valves 142, 146 and/or the sequence in which the pulses from thesensors 80, 84 occurred in determining and cataloging the exceptionevent.

The sensor system 102 can also provide real time statistics ofdispensing performance for the bin 100, as well as a record of theperformance of the bin 100.

While the sensor system has been described hereinabove with regard tothe bin 100 and the dispensing system 40, sensor systems according toembodiments of the present invention may be used with bins and/orsystems of other types and configurations. Sensor systems according toembodiments of the present invention may include sensors differentlyconfigured than the sensors 80, 84.

While embodiments employing forced gas drive mechanisms are describedherein, other embodiments of the present invention may employ otherdrive mechanisms in place of or in addition to forced gas. For example,the pharmaceutical articles may be forced in the forward and/or reversedirection by vibration and/or gravity.

While various methods are described herein to identify dispensing faultconditions, these methods may also serve to confirm proper countconditions. More particularly, the lack of identification of adispensing fault condition may be registered or affirm a valid count orcount session. Accordingly, sensor systems as disclosed herein mayprovide improvements in count confidence.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention. Therefore,it is to be understood that the foregoing is illustrative of the presentinvention and is not to be construed as limited to the specificembodiments disclosed, and that modifications to the disclosedembodiments, as well as other embodiments, are intended to be includedwithin the scope of the invention.

1. A method for dispensing solid pharmaceutical articles using anapparatus including a housing and a sensor system, the housing defininga dispensing channel having a dispensing inlet and a dispensing outletdownstream of the dispensing inlet, the sensor system including firstand second sensors spaced apart along the dispensing channel such thatthe second sensor is located downstream of the first sensor, the methodcomprising: forcing at least one article along a path through thedispensing channel; generating detection signals using the first andsecond sensors responsive to articles passing through the dispensingchannel; and using the detection signals from the first and secondsensors to monitor dispensing performance of the apparatus.
 2. Themethod of claim 1 wherein the first sensor is located proximate thedispensing inlet and the second sensor is located proximate thedispensing outlet.
 3. The method of claim 1 including counting thearticles passing through the dispensing channel using at least one ofthe first and second sensors.
 4. The method of claim 3 including:counting the articles passing through the dispensing channel using thesecond sensor; and detecting jams of the articles using the firstsensor.
 5. The method of claim 1 wherein forcing at least one articlealong the path through the dispensing channel includes generating atleast one drive gas flow using a flow generator to force the at leastone article along the path through the dispensing channel.
 6. The methodof claim 5 including forcing the articles through the dispensing channelusing a drive gas jet.
 7. The method of claim 5 including positivelycontrolling a positive pressure source to provide the at least one drivegas flow.
 8. The method of claim 1 including dispensing the articlesfrom a hopper chamber of the housing into the dispensing channel. 9-28.(canceled)
 29. A method for dispensing solid pharmaceutical articlesusing an apparatus including a housing and a sensor system, the housingdefining a dispensing channel having a dispensing inlet and a dispensingoutlet downstream of the dispensing inlet, the sensor system includingat least one sensor positioned along the dispensing channel, the methodcomprising: forcing at least one article along a path through thedispensing channel; generating detection signals using the at least onesensor responsive to articles passing through the dispensing channel;and using a duration of at least one of the detection signals from theat least one sensor to determine whether a dispensing fault conditionhas occurred.